B2CG1EK1 - 406D9 ML5T GEARBOX

REMOVAL - REFITTING GEARBOX

1 - SPECIAL TOOLS

[2] Tool for unclipping 13 dia. ball joints (-).0216-G2 .

[3] Tool for unclipping 10 dia. ball joints (-).0216-G1 .

[4] Clutch stop clipping tool (-).0216-K .

[5] Clutch plate centralising mandrel (-).0216-C .

1 model .

Retaining bar (-).0911 :

• [6] cross beam and adjusting screw (-).0911-A1
• [7] cross beam support (-).0911-A2

[8] lifting hook (-).0102-J .

2 model .

[9] Power train support crossmember (-).0009 .

[10] fitting drift for final drive right-hand output oil seal (-).0332-B .

[11] fitting drift for final drive left-hand output oil seal (-).0332-A .

[12] ball joint extractor (-).0709 .

2 - REMOVAL

NOTE : the gearbox is removed from under the vehicle .

Disconnect the battery .

IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand the torsion, traction or bending tensions caused by the removal of one of the power train supports .

Remove the shields under the power train .

Remove :

• the style cover (1)
• the air cleaner and its bracket (2)
• the turbo pipe (3)
• the driven accelerator cable (according to specification)

Drain: The gearbox .

Remove the engine speed sensor .

Drain the brake fluid reservoir using a clean syringe .

Drain the hydraulic circuit (Hydraulic clutch control) With the bleed screw .

Move aside the clip, Without removing .

Move aside the pipe (5) .

Release the slave cylinder (6) from the hydraulic control (by pressing in the direction of the arrow (A) and slackening in the direction of the arrow (B), anti-clockwise) .

Detach the control from its bracket (4) and move it aside .

WARNING : do not use any tools to unfasten the cylinder do not press the clutch pedal with the slave cylinder removed .

Remove :

• the clips (7)
• the gear lever ball-joints (8) and (9) using the tools [2] and [3]

Disconnect, unclip and move aside the electrical harnesses which are connected to the gearbox .

Remove the securing bolts (10) .

Move aside the starter without disconnecting it .

Remove :

• the subframe with the steering
• the turbocharger air pipe (11)
• the closing plate (12)
• the right-hand drive shaft (13)
• the torque reaction link

Disengage the left-hand drive shaft (14) .

Attach a crane to the gearbox with the hook [8] .

Remove :

• the gearbox shaft nut (15)
• the washer (16)
• the shim bolt (17)
• the flexible mounting (18)
• the gearbox support (19)

Lower the power unit .

1 model .

Position :

• the crossmember [6] and its brackets [7]

2 model .

Position the crossmember [9] and its brackets .

WARNING : position the contact points at (C) .

Remove :

• the lower bolts securing the gearbox on the engine
• the gearbox

3 - REFITTING

Always renew :

• the O ring (20) of the bearing stop plate (21)
• the final gear outlet lip seal (22) using the tool [11]
• self-locking nuts
• the spring washers

Always renew :

• the final gear outlet lip seal (23) using the tool [10]

WARNING : ensure that the gearbox locating pins are fitted .

Coat lightly with MOLYKOTE BR2 PLUS grease :

• the gearbox input shaft splines
• the release bearing guide sleeve
• the fingers of the fork

Fill the space between the oil seal lips with grease .

Clean the bolt threads .

On refitting, the stop must be on its guide and positioned by the declutching fork .

The stop is clipped to the mechanism after the gearbox has been assembled on the engine .

Refit the clutch .

Attach the gearbox to the engine : Tighten the bolts to 6 da.Nm .

Reclip the clutch stop :

• insert the tool [4] in the oblong hole in the clutch fork
• rotate the tool [4] by 90 °
• pull, using the handle, to clip the stop
• check that it is correctly clipped by pushing the tool (the stop should not fall back)

Proceed in the reverse order to removal .

WARNING : on refitting the hydraulic cable, check that the rod is correctly positioned, press the clutch pedal several times .

WARNING : do not forget to refit the toothed washers between the steering rack and the sub-frame .

Fill the gearbox: 1.850 litre(s) .

4 - TIGHTENING TORQUES

Bolt which secures the gearbox to the engine 6 da.Nm .

Bolt which secures the gearbox mounting 4.5 da.Nm .

Bolt which secures the flexible mounting to its bracket 3 da.Nm .

Gearbox mounting shaft nut 6.5 da.Nm .

Starter securing bolt 3.5 da.Nm .

Closer plate securing bolt 2 da.Nm .

Drive shaft bearing fastenings 1.75 da.Nm .

Pivot ball joint nut (24) to 5 da.Nm .

Anti-roll bar rod fastener (25) 6.5 da.Nm .

Steering ball joint nut (26) 3.5 da.Nm .

Bolt(s) (27) securing the sub-frame to the body to 12 daNm .

Drive shaft nut to 28 m.daN (5 lbf.ft) .

Fastener (29) securing the torque reaction link to the flexible mounting: 5 da.Nm. .

Torque reaction link fixing (30) to engine sub frame 8.5 da.Nm .